APS, Air processing system - Function

Function
   General function description
   Modules and components in the APS unit
   Air dryer
   Circuit protection valve
   Control unit
   Pressure levels in the APS unit
   APS unit functions during normal operation
   APS unit functions in the event of malfunction

Function   
General function description
The APS unit manages the air pressure in the compressed air system. The incoming air from
the compressor is dried and cleaned. In the event of a pressure drop in one circuit, the
other circuits are protected from a pressure drop. The APS unit has pressure sensors which
read off and transmit information about the air pressure in the parking brake, front circuit
and rear circuit to the instrument cluster via CAN communication. The normal pressure
range for the system is between 9.0 and 12.3 bar. At an air pressure of 5.5 bar the brake
pressure lamp in the instrument cluster flashes and the buzzer sounds.

The APS unit uses the circuit protection valve to regulate the order in which the circuits are
filled with air. The APS unit also controls the compressor and regeneration with solenoid
valves which are controlled by the control unit. The compressor and regeneration are not
only controlled by the air pressure in the pneumatic system, they also take into account
other parameters such as a request for compressed air from the rear axle air suspension.
The APS control unit continuously attempts to reduce the load on the engine in order to
save fuel, and therefore primarily charges the pneumatic system when the vehicle is engine
braking.
 

Modules and components in the APS unit

The air dryer (1) consists of an air dryer housing and desiccant container. The circuit
protection valve (2) consists of four protection valves, one for each circuit, and one priority
valve, which ensures that the parking brake and trailer brake circuit are not charged until
sufficient pressure has built up in the service brake circuits. The control unit (3)
communicates with the rest of the vehicle through CAN communication and checks and
regulates the compressor and regeneration function.
 

1. Air dryer
2. Circuit protection valve
3. Control unit

Air dryer
The air dryer consists of the following parts:
 

Desiccant container (1):

The desiccant container contains desiccant, which binds moisture and prevents water and
moisture from entering the compressed air system. The desiccant is dried during
regeneration when air from the compressed air system blows through the desiccant and out
of the system through the drain valve.

Check valve (2):

The check valve prevents the compressed air from the circuit protection valve from flowing
back into the air dryer and prevents the compressed air system from evacuating.

Pressure limiting valve (3):

The parking brake and trailer brake circuit contain pressure-sensitive components. The
pressure limiting valve limits the pressure to 8.5 bar in these circuits.

Safety valve (4):

The safety valve has an opening pressure of 13-14.5 bar and limits the air pressure by
evacuating air from the pneumatic system when the air pressure is too high.

Drain valve (5):

The drain valve opens when the desiccant is regenerated. The valve is controlled by air from
the regeneration solenoid valve.

Intermediate piece for connecting the regeneration tank (6):

It is possible to convert a standard APS unit to a high-capacity APS unit by using an
intermediate piece for connecting a regeneration tank.

The intermediate piece is fitted between the air dryer and circuit protection valve of the APS
unit and provides an additional port. There is a connection on the intermediate piece which
is used to connect a pipe to an extra compressed air tank (regeneration tank).

The extra compressed air tank together with the intermediate piece allows a large quantity
of air to pass the desiccant container during regeneration. The higher air flow releases
moisture from the desiccant more effectively and regeneration therefore proceeds much
more quickly. The shorter regeneration time enables the APS unit to be in charging mode a
greater percentage of the time and thereby deliver more dried air to the compressed air
system.

Circuit protection valve

WARNING!

To ensure functionality of the circuit protection valve, it must not be disassembled. A faulty
circuit protection valve entails a risk of accidents when the vehicle is brought into operation
in traffic.

In the event of a pressure drop in one of the circuits, the circuit protection valve protects
the other circuits from losing air pressure.

The circuit protection valve also controls compressed air system charging. To ensure that
the parking brake cannot be released before the front and rear circuits have sufficient air
pressure for braking, the circuit protection valve regulates the air supply so that no air is let
into the parking brake circuit before there is sufficient air pressure in the front and rear
circuits. If the front circuit is depressurised, the parking brake circuit will be drained through
the bypass valve (10).

The circuit protection valve contains the following components:

 

Protection valve for the air suspension circuit (1):

The protection valve for the air spring circuits opens at 8.5 bar and closes at ≤ 4.5 bar. To
facilitate the charging of the air bellows when the compressed air system has been empty,
there is a bypass valve which allows the circuit to start being filled before the protection
valve has opened. The flow is 50 litres per minute at 6.0 bar.

Protection valve for the rear circuit (2):

The protection valve for the rear circuit opens at 7.5 bar and closes at ≤ 4.5 bar.

Protection valve for the front circuit (3):

The protection valve for the front circuit opens at 7.5 bar and closes at ≤ 4.5 bar.

The priority valve (protection valve) for the trailer brake and parking brake circuit
(4):

The opening pressure of the priority valve remains between 6.0 and 7.5 bars. In order for
the valve to open, it is also necessary for the combined pressure of the service brake
circuits to reach at least 7.2 bar. This is to ensure that the parking brake cannot be released
until the service brakes have sufficient pressure. The priority valve closes at ≤ 4.0 bar.

Protection valve for the accessory circuit (5):

The protection valve for the accessory circuit opens at 7.5 bar and closes at ≤ 4.5 bar. To
allow the activation of the white smoke limiter before the protection valve has opened, there
is also a bypass valve (6).
Regeneration solenoid valve (7):

When the solenoid valve is open, the compressed air flows from the compressed air system
through the solenoid valve, which opens the drain valve. Compressed air flows backwards
through the air dryer out through the drain valve.

Regeneration check valve (8):

The check valve prevents supply air from flowing into the control pipe and on to the drain
valve when the compressed air system is being charged. The restriction limits the air flow
through the desiccant container during regeneration.

Solenoid valve for compressor control (9):

When the solenoid valve is active, the control line is pressurised and the compressor is
relieved. When the compressor is activated, compressed air is evacuated from the control
pipe through the solenoid valve and on via a drain valve, position 3.2 in the diagram.

Bypass valve (10):

Bypass valve which drains air from the parking brake circuit to the front circuit. This occurs
if the air pressure in the front circuit drops below the air pressure in the parking brake
circuit. The flow is between 35 and 55 litres per minute at 6.0 bar.

Circuit priority function

The pressure values in the table below can be difficult to measure and may vary depending
on the measurement method used. These pressure values should only be used as a guide
when troubleshooting. A deviating pressure value does not necessarily mean that there is a
fault in the circuit protection valve or any other component in the compressed air system.

Circuit Opening pressure Closing pressure

21 (Rear 7.5 bar ≤4.5 bar

circuit)

22 (Front 7.5 bar ≤4.5 bar

circuit)

23 (Trailer 6.0-7.5 bar, at front and rear circuit ≤4.0 bar

brake and ≤7.2 bar
Parking
brake
circuit)

24 7.5 bar ≤4.5 bar

(Accessory
circuit)
 25 (Air 8.5 bar ≤4.5 bar
suspensio
n circuit)

Block circuit coupling

Manifold fitting for connection to the various brake system circuits.

 A1: Accessory circuit

 A2: Accessory circuit
 A3: No connection
 A4: Test connection for the front circuit
 A5: Test connection for the parking brake circuit
 A6: Front circuit
 B1: Test connection for the rear circuit
 B2: Rear circuit
 B3: Rear circuit
 B4: Parking brake circuit
 B5: Air suspension circuit
 B6: Test connection for the air suspension circuit

Control unit
The control unit is available in several different versions and consists of the following parts:
Circuit board, connectors, temperature sensor and pressure sensor
 

The figure illustrates a control unit with three pressure sensors.

Temperature sensor (1):

The temperature sensor value is used to obtain a calculated temperature at the drain valve.
When the calculated value approaches zero degrees Celsius, the APS unit switches to
heating mode.

Pressure sensor for the rear circuit (2):

Information from the rear circuit pressure sensor is transmitted via CAN communication and
is displayed in the instrument cluster.

Pressure sensor for the front circuit (3):

Information from the front circuit pressure sensor is transmitted via CAN communication
and is displayed in the instrument cluster.

Pressure sensor for the parking brake circuit (4):

Information from the parking brake circuit pressure sensor is transmitted via CAN
communication to the instrument cluster. If the air pressure is below 5.5 bar the brake
pressure lamp flashes and the buzzer sounds.

Connector (5):
 

 1: Voltage (30 supply)

 2: Ground
 3: Voltage (15 supply)
 4: CAN High
 5: CAN Low
 6: No connection
 7: No connection

Pressure levels in the APS unit

A, Vehicles with normal pressure level

Note:There are two designs of APS control unit. Control units manufactured after November
2005 allow regeneration from 9.0 bar. Earlier versions of control units allow regeneration
from 7.5 down to 6.0 bar.

1. Engine braking and request for pressure increase.

2. Normal mode.
3. Intermediate regeneration.
4. Minimum pressure for intermediate regeneration.
5. 11.8-12.3 bar, lower and upper limit for engine brake and ELC.
6. 11.0-11.8 bar, compressed air buffer.
7. 10.0-11.0 bar, regeneration.
 8. 9.0-10.0 bar, intermediate regeneration.
9. 0-9.0 bar, no regeneration.

B, Vehicles with unlimited load transfer and certain special vehicles

1. Engine braking and request for pressure increase.

2. Normal mode.
3. Minimum pressure for regeneration.
4. 12.0-12.5 bar, lower and upper limit for engine brake and ELC.
5. 11.0-12.0 bar, regeneration.
6. 0-11.0 bar, no regeneration.

C, Vehicles with reduced pressure level

Applies to vehicles without EBS, manufactured between June 2008 and October
2009.

 
 1. Engine braking and request for pressure increase.
2. Normal mode.
3. Intermediate regeneration.
4. Minimum pressure for intermediate regeneration.
5. 10.3-10.8 bar, lower and upper limit for engine brake and ELC.
6. 9.3-10.3 bar, regeneration.
7. 9.0-9.3 bar, intermediate regeneration.
8. 0-9.0 bar, no regeneration.

APS unit pressure levels during heating mode

Applies to A (vehicles with normal pressure level) and B (vehicles with unlimited
load transfer and certain special vehicles)

1. 11.0-11.5 bar, regeneration without relieving the compressor.

2. 0-11.0 bar, no regeneration during warm-up phase.

Applies to C (vehicles with reduced pressure level)

 
 1. 9.5-10.0 bar, regeneration without relieving the compressor.
2. 0-9.5 bar, no regeneration during warm-up phase.

APS unit functions during normal operation

During normal operation the compressor is activated at a minimum of 10.0-10.5 bar.
Depending on how much air is required for regeneration, the compressor is deactivated
somewhere between 10.5 and 11.0 bar. This is to ensure that the air pressure is a minimum
of 10.5 bar after regeneration.

Engine braking

During engine braking, when engine torque is used to charge air without increasing fuel
consumption, the compressor is activated if the air pressure is below 11.8 bar and
deactivated at 12.3 bar at the latest.

Request for pressure increase

If the air suspension is activated during engine braking, the air pressure may drop below
11.0 bar. The air suspension system transmits a request to the APS unit for an increase in
pressure. If regenerations have been suppressed for a long period, regeneration will be
prioritised above a pressure increase until the compressed air system has managed to dry
the desiccant.

Regeneration

During regeneration, the desiccant is dried when air from the compressed air system blows
through the desiccant and out of the system through the drain valve. There is a function in
the APS unit that calculates how much air passes through the air dryer. The air consumption
counter counts up when the compressor is charging and counts down during regeneration.
The counter value determines when the air dryer needs to be regenerated. The lowest level
for regeneration is 10.0 bar.

Intermediate regeneration

When air consumption is high and regeneration has not been possible for a long period, the
air consumption counter in the APS unit will reach a high value. One or more regenerations
will take place to get the value on the counter down. The lowest level for regeneration is
reduced from 10.0 to 9.0 bar. If the air consumption is very high, fault code 727 is
generated.

Parked vehicle

When the starter key is switched off, the APS unit carries out a regeneration to ensure that
the compressed air system is dry. Regeneration can carry on for up to one minute.
Heating mode

If the temperature in the air dryer drain valve is close to freezing, a function for heating the
APS unit is started using hot air from the compressor. The compressor is active and the
drain valve is open. When the function is active, the compressor is activated at 11.0 bar and
deactivated at 12.3 bar.

The APS unit will switch between the normal mode and heating as long as heating is
necessary.

APS unit functions in the event of malfunction

Mechanical mode

If CAN communication is interrupted or there is an internal fault in the APS unit, it operates
in mechanical mode.

Mechanical mode means that the compressor is relieved, and regeneration occurs at a fixed,
predefined air pressure. The compressor is activated at 10.0 bar and deactivated at 12.3
bar. At 12.3 bar regeneration takes place down to 11.7 bar.

Back-up mode

When the APS unit cannot measure the air pressure in the front and rear circuits, the air
pressure in the compressed air system is regulated by the air dryer safety valve. The air
pressure is a maximum of 13-14.5 bar, and the compressor is continuously active.

Note:Renew the safety valve if the APS unit has been in back-up mode for a long period.
The opening pressure drops if the safety valve is used for a long period.

Pressure limitation if the air pressure is too high in the front and rear circuits

If the air pressure rises above 13.0 bar in the front or rear circuit, a yellow warning is
displayed in the instrument cluster. The APS unit lowers the air pressure to 12.5 bar. If this
happens there is usually a leak in the control line to the compressor.

Pressure limitation if the air pressure is too high in the parking brake and trailer brake circuit as
well as the accessory circuit

If the air pressure rises to 9.0 bar in the parking brake circuit, trailer brake circuit and
accessory circuit, the APS unit lowers the pressure to 8.1 bar throughout the pneumatic
system, including parts which are normally not pressure limited.

If the APS control unit is defective, the pressure limiting valve acts as a safety valve for the
parking brake circuit, trailer brake circuit and accessory circuits and releases air at 9.2 bar if
the air pressure gets too high.

APS, Air processing system - Overview

Overview - APS unit

Overview - APS unit compressed air flow

Overview - Schematic diagram for vehicles without auxiliary regeneration tank

Overview - Schematic diagram for vehicles with auxiliary regeneration tank

Overview - APS unit   

A (air dryer)

1. Desiccant container

2. Regeneration check valve

3. Drain valve (venting)

4. Silencer

5. Pressure limiting valve

6. Safety valve
 B (circuit protection valve)

7. 24, Accessory circuit

8. 22, Front circuit

9. 23, Trailer brake and parking brake circuit

10.21, Rear circuit

11.25, Air suspension circuit

12.Solenoid valve for regeneration

13.Solenoid valve for compressor control

Overview - APS unit compressed air flow   

 A, 10.0-12.3 bar, compressed air supply to circuits 21, 22 and 25.

 B, 8.5 bar, compressed air supply to circuits 23, 24 and the solenoid valves.
 C, 0 bar, control pressure for the drain valve.
 

 A, 10.0-12.3 bar, compressed air supply to circuits 21, 22 and 25.

 B, 8.5 bar, compressed air supply to circuits 23, 24 and the solenoid valves.
 C, 0.1 bar, for regeneration.
 D, 8.5 bar, control pressure for the solenoid valves.

Overview - Schematic diagram for vehicles without

auxiliary regeneration tank   
 

1. Air dryer
2. Protection valve
3. Control unit with pressure sensor

Inlet and outlet:

 1.1: Supply from the compressor.

 1.2: External charging.

 3: Venting (Drain valve)

 3.1: Safety valve

 3.2: Outlet for air which is evacuated from the solenoid valves.

 4: Control signal to the compressor.

 21: Rear circuit

  22: Front circuit

 23: Parking brake circuit

 24: Accessory circuit

 25: Air suspension circuit

Overview - Schematic diagram for vehicles with auxiliary

regeneration tank   

1. Air dryer
2. Protection valve
3. Control unit with pressure sensor

Inlet and outlet:

 1.1: Supply from the compressor.

 1.2: External charging.

 3: Venting (Drain valve)

 3.1: Safety valve

 3.2: Outlet for air which is evacuated from the solenoid valves.

 4: Control signal to the compressor.

 21: Rear circuit

 22: Front circuit

 23: Parking brake circuit

 24: Accessory circuit

 25: Air suspension circuit

 29: Intermediate piece for connecting the regeneration tank.